Xano Sweeting | Portfolio

Formula SAE Motorsports

Custom Fuse Design and Testing

I designed custom fuses for P42A 27100 battery cells, that I lasercut and then characterized.

Battery Module M2

I manufactred the battery packs by lasercutting nickel conductor plates then glueing the cells together and spotwelding the plates to the cells. My design had a few problems both with manufacturing and the overall product but I was able to solve them in my next iteration.

Battery Module M3 in the works

16s 6p battery pack, capable of 15.5kw peak output (270 amps peak at 57.6 Volts). This battery pack is much faster to manufacture than my previous design. It includes flame retardant, thermal potting which ensures thermal homogeneity within the pack.

I also designed a custom BMS breakout board that fits into the top of the pack:

Exascale Systems

At exascale systems I helped design and fabricate various parts of the motion system for a crystal growth arc furnace.

Picture of arc furnace with 3D printed mounts for protected raspi camera and limit switch mounts:

Motion Controller For Arc Furnace

I used DB9 connectors and breakoutboards for stepper motors and limit switches. I milled the pcb out of blanks, soldered all the components and programmed the ‘teensy’ microcontroller. There were three electrodes in the arc furnace. Each had one stepper for depth and one for tilt.

New Amsterdam Metalworks

Robotic Kitchen Hood

I designed a kitchen hood that actuated up and down at the push of a couple buttons. The project entailed mechanical design, machining, welding, circuity, and controls programming.

Steel Roof Deck

I surveyed the site, made architectural drawings, machined and welded various parts for a steel roof deck structure.

Robotics

Robot In One Night

I designed, printed, programmed and built this little bottle cap stacking mecanum robot in one night for a college competition.

Rack and pinion mechanism in action

PID Steering Correction

First Robotics League

As Team Captain

During my senior year of high school (2020 COVID), I led a team in remotely creating an almost fully 3D printed Robot. We built the robot with less than half the budget the team is usually alloted. I slept with 3D printers running 24/7 for a couple months. It was a year that most urban teams didn’t compete, but taking inspiration from James Burton, I knew we could if we wanted.

Together we were able to build 5 large mechanisms in seperate homes and then bring those together in mine for a full robot.

As Team Member

Junior year of highschool,this robot taught me to CAD. I designed the chassis, the roller intake and did the full 1200 part assembly for my team:

Embedded tank drive

Roller Intake

Misc Projects

Longboard

I laminated my own plywood. Then I cut, sanded, routed and finished the longboard I used to get to school everyday for two years.

Solar Longboard

Music with LEDs

LED Mushroom

This mushroom syncs with music over wifi using an esp8266 and the WLED library.

LED Eye

TIP31C

One of my favorite LED projects that I do whenever I can. A simple music visulizer using a transistor.

Video is a lot cooler with sound ofc.

Piezo Flexure Plate

Bicycles

I love bicycles. I’ve been riding them since I was four and to this day they are my favorite form of catharsis because they combine working with my hands, exploring and exercise.

Carbon fiber Seatpost

This was my first ever CAD project. The bike frame I bought for cheap turned out to have no seatpost with it. I couldn’t find the proprietary part or drawings for it anywhere on the internet. I thought I might be able to 3D print a bicycle seatpost. Ended up using a 3D print as a core mold for a carbon fiber layup.

Craigslist bike Restorations

High School E-Bike

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My Lovely Track Bike

iPhone Repair Business

Housing Swaps

Collected Broken LCDs

My Rummagings